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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 05:34 AM
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Now comes the part i should have started with first i was afraid i would break the windshield getting it out but luckily my wife helped me out and we took our time and got it out with out breaking it.

First i cut across the roof behind the windshield and moved the window frame and the roof to approximately where i wanted it .



Here you can see that the roof line at the top of the windshield is flat , this dosent match the curve of the windshield this was also fixed.


















Here is with the windshield setting back in the opening with the roof curved to match the windshield now.









Here is the difference in the hight of the roof to the top of the door before i remade the window frame.









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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 05:56 AM
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Now comes the drivers side door i admit i should have taken more pics of the process but if there is anything not seen here you would like to know i can explane (hopefully) for anybody to understand.


First i start at the back of the door and make the latch pocket.










Then i make the lower extension, you will notice the lip on this piece this is where the skin will be welded to later on this also serves to help me see where the inner door frame is in relation to the body.






Now i built the lower potion of the door , this was quite easy just a simple straight piece with the 90deg bends









Ok now here is where my photo diary skills are lacking i got so busy building the door i stupidly forgot to take any pictures of the door frame being built and the inner door structure being built .

Baiscaly the top door frame is made of two layers of .063 aluminum, an outer and a inner section welded together to form the window frame this makes the door quite rigid and strong across the top and still be light once the window channel was welded on this door is very strong across the top .















You cant see it very well in this pic but the pocket in the fender where the door opens into i enclosed this section also so dirt and grim from the front tires wouldnt be able collect and get into the door jam something i had a problem with before.


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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 07:03 AM
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Here is the window regulator im decided to go with im changing the pass door to accept the regulator also this is much simpler that the original cable and pulley setup i was going to use les parts to fail.

This regulator is out of a cavalier im not sure the year i will have to find out but i seems to work just fine i have some electric motors for the regulators so i will make them power instead of manual.















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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 07:12 AM
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Now i started on the outer door skin ,first i start making the top plate.









Then i move to the actual door skin, first i planshed the skin to get the curve to match the quarter panel and the fender i left the skin long intentionally, so i could trim it to fit as i was welding it to the top plate,this whole process took about 2 hours to complete as you have to work slowly to make sure everything lines up and you dont wrinkle the skin .

[img]


Here you can see my door gaps are very tight on the door to fender, later after i welded the skin on complete i can go back with a file and file fit my gaps.









I didnt get any pics as i was building the scoop into the door but this was a simple process and shouldnt be hard to do if you got this far building the door.

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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 07:21 AM
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Now on to the primer stage for the front half.
























At this point i have the front suspension complete , first coat of slick sand primer and the doors fitting half way decent gaps still need work and plenty of blocking.






.

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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 07:27 AM
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At this point the front half is ready to go i remade the front trunk hinge, and some other minor stuff, nothing major, the back half of the car mainly need some touch up work done nothing major on that end to get read for paint.

Here is some outside shots.











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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 07:32 AM
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Here it is ready for paint i dont have a booth since i dont spray that many cars so please forgive the country style paint job.LOL



















Here is a pic of the turn signal bucket the big holes around the seal are for the trim rings i made that hole the covers for the lenses.


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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 07:48 AM
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This was the new paint job still need buffing and lot of finish work but getting there.

The red interior is also going is was in need of a redo anyway.LOL

You can see the trim rings setting in the turn signal opening in the pic also.





























































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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 08:25 AM
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Next i pulled the drive train and rear K member out , striped,and repainted everything in the rear of the car i redid the wiring cleaned up some things relocated my MSD and my fuel injection relay board to the drivers quarter.

I am also going to have my exhaust and turbo housings coated this spring (hopefully) as they rather nasty right now.

























This is when im at as of now im not going to work on it till this spring most likely, its too cold here now for me to be messing with it in the shop, plus i would rather take the time off so i dont get burnt out, and take some time to think about the next steps im going to take to finish this thing, thanks to everyone for the kind words of encouragement so far, i have learned so much from building this car three times hopefully this is the last time i will leave you guys with the video i made hope you guys like.



http://www.youtube.com/watch?v=Ut90rhCzvVY

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Last edited by turbo355 on Dec 17, 2009 - 11:48 PM; edited 2 times in total
 
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khs_racerOffline
Post subject:   PostPosted: Dec 17, 2009 - 01:17 PM
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Very nice work, time for a break.
 
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flyhilandsoft
Post subject:   PostPosted: Dec 17, 2009 - 03:06 PM
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I really like the way your car sits. Low.....with very accurate lines. Nice job!

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Goodyear, Az
"Its a dry heat"

http://www.siennacountach.net/gallery2/album129?page=1

http://countachbuild.shutterfly.com/pictures#:albumId=2303
Password-aluminum
 
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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 11:42 PM
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khs_racer wrote:
Very nice work, time for a break.


Thanks for the kind works,yeah my wallet agrees.LOL

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turbo355Offline
Post subject:   PostPosted: Dec 17, 2009 - 11:44 PM
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flyhilandsoft wrote:
I really like the way your car sits. Low.....with very accurate lines. Nice job!
Thank you very much. Very Happy

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chrisbarbersOffline
Post subject:   PostPosted: Dec 18, 2009 - 09:08 AM
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nice job and great pics, doors look great.
 
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lambobuilderOffline
Post subject:   PostPosted: Dec 18, 2009 - 12:44 PM
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Great job. Thanks for all the detailed photos. That is difficult to remember to take pictures as you go.

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